Skoda Octavia Mk1 - 06 - Power Transmission Gearbox 02K

8/16/2019 Skoda Octavia Mk1 - 06 - Power Transmission Gearbox 02K

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SKODA OCTAVIAMK1

Power transmission5 speed Manual gearbox !K


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POWER TRANSMISSION.....................................................................................................4

5 SPEED MANUAL GEARBOX 02K........................................................................................4

TECHNICAL DATA.............................................................................................................. 4

ID"#TI$ICATIO# O$ T%" &"A'(O)******************************************************************************************************************+

Location on the gearbox up to 06.99.................................................................................................4Location on the gearbox as of 07.99.................................................................................................6

Identication characters, aggregate assignment, ratios, capacities..................................................7

OV"'VI", O$ T'A#SMISSIO# S -ST"M**********************************************************************************************************11

&"#"'A. '"PAI' I#$O'MATIO#*******************************************************************************************************************1/

CLUTCH, CONTROL..........................................................................................................18

'"PAI'I#& C.0TC% CO#T'O.**********************************************************************************************************************1

Overvie......................................................................................................................................... !"

#ummar$ of components % &oot contro's.........................................................................................!9

(emoving and insta''ing the over%centre he'per spring...................................................................))

(emoving and insta''ing the c'utch peda'........................................................................................)*

(emoving and insta''ing c'utch peda' sitch %&*6%..........................................................................)4

'emo2ing and installing t3e 4lut43 pedal swit43 $/6 7angular 3ousing8*****************************************************!+

'emo2ing and installing t3e 4lut43 pedal swit43 $/6 7round 3ousing8******************************************************* !5

#ummar$ of components % +$drau'ics.............................................................................................)

-hec h$drau'ic c'utch contro'........................................................................................................)"

(emoving and insta''ing the master c$'inder..................................................................................*0

(emoving and insta''ing the s'ave c$'inder.....................................................................................*4

/'eeding the c'utch s$stem.............................................................................................................*

'"PAI'I#& C.0TC%***********************************************************************************************************************************/9

&au't nding poer transmission % prob'ems ith the c'utch and c'utch contro'.............................*7

#ummar$ of components % repairing the c'utch...............................................................................4)

(emoving and insta''ing c'utch.......................................................................................................44

GEARBOX MECHANICS,OPERATION, CONSTRUCTION,DIFF..................................................48

'"PAI'I#& T%" &"A'S%I$T M"C%A#ISM********************************************************************************************************+

&itting 'ocation of shift mechanism..................................................................................................4"

#ummar$ of components % shift housing shift 'ever......................................................................0

(emoving and insta''ing shift housing ith shift 'ever and shift rod................................................*

(emoving and insta''ing shift 'ever from shift housing....................................................................7

#ummar$ of components % reverse%shift mechanism at the gearbox.............................................."

#etting the shift mechanism............................................................................................................6*

'"MOVI#& A#D I#STA..I#& T%" &"A'(O)****************************************************************************************************6

(emoving the gearbox.................................................................................................................... 6" Transporting t3e gearbox***************************************************************************************************************************** 99

Insta''ing the gearbox...................................................................................................................... 7"

Tig3tening tor:ues*************************************************************************************************************************************** 9;

I#SP"CT &"A' OI.************************************************************************************************************************************ +

DISASS"M(.I#& A#D ASS"M(.I#& T%" &"A'(O)********************************************************************************************6

1earbox overvie........................................................................................................................... "6

#ummar$ of components % disassemb'ing and assemb'ing the gearbox........................................."7

#ummar$ of components % (emoving and insta''ing gearbox housing cover and th gear.............""

#ummar$ of components % removing and insta''ing gearbox housing and shift mechanism...........90

#ummar$ of components % (emoving and insta''ing the drive shaft, output shaft, di2erentia' gear

and shift fors................................................................................................................................. 94

3ounting seuence % disassemb'ing and assemb'ing the gearbox..................................................9"

Disassembling gearbox******************************************************************************************************************************** ;

Assembling gearbox*********************************************************************************************************************************** 11

(epairing gearbox housing and gearshift shaft.............................................................................!))

!


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(epairing c'utch housing...............................................................................................................!)7

(epairing gearbox housing cover..................................................................................................!*4

DISASS"M(.I#& A#D ASS"M(.I#& T%" D'IV" S%A$T*************************************************************************************1/;

5isassemb'ing and assemb'ing the drive shaft.............................................................................!*9

O0TP0T S%A$T************************************************************************************************************************************** 15

5isassemb'ing and assemb'ing the output shaft...........................................................................!0

#etting output shaft...................................................................................................................... !"

FINAL DRIVE, DIFFERENTIAL, DIFFERENTIAL LOCK..........................................................12

'"P.ACI#& T%" $.A#&" S%A$T &ASK"T 'I#&S 7&"A'(O) ASS"M(."D8*************************************************************16!

(ep'acing the 'eft ange shaft gaset ring....................................................................................!6)

'emo2ing*************************************************************************************************************************************************** 16!

Install********************************************************************************************************************************************************* 16/

(ep'acing the right ange shaft sea' ring......................................................................................!6*

'emo2ing*************************************************************************************************************************************************** 16+

Install********************************************************************************************************************************************************* 16+

DI$$"'"#TIA. &"A'******************************************************************************************************************************* 166

5isassemb'ing and assemb'ing the di2erentia' gear.....................................................................!66

d8usting the di2erentia' gear....................................................................................................... !7

S"TTI#& OV"'VI",******************************************************************************************************************************** 1

/


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Power transmission

5 speed Manual gearbox !K

Te43ni4al Data

Identi C3apter*

.o4ation on t3e gearbox as o= 9*;;

Identi


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Identification characters and manufacturing data

of the gearbox on the bottom of the clutch

housing -arrow 1-

Gearbox 02K -arrow 2-


of the gearbox -arrow 1-

Example: C! 2" 0# $

I I I I

I I I I

Identification characters !a% &onth &anufacturing %ear -1''$-

(dditional data depend on the manufacturing)

*ote

+he gearbox identification characters also appear on the ,ehicle data sticers)

5


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.o4ation on t3e gearbox as o= 9*;;


of the gearbox on the top of the clutch housing

-arrow 1-



of the gearbox -arrow 1-

6


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Example: !.. 1/ 0' '

I I I I

I I I I

Identification characters !a% &onth &anufacturing %ear 1'''

(dditional data depend on the manufacturing)

*ote

+he gearbox identification characters also appear on the ,ehicle data sticers)


Identi


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Clut43 4ontrol 3Edrauli4

Clut43 dis4 diameter F > "le4troni4 Catalogue o= Original Parts

Dri2e s3a=t Gange F ; mm

Identi "le4troni4 Catalogue o= Original Parts


Identi


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+t3 gear /! /1 1?/! /1 /! ?;6; /! /1 1?/!

5t3 gear /+ + ?5 // +1 ?5 /+ + ?5

'e2erse gear / 1! /?169

Speedometer !?1+

Capa4itE 1*; litres

Spe4i "le4troni4 Catalogue o= Original Parts

&ear oil 43ange inter2al $illed =or li=e

Clut43 4ontrol 3Edrauli4

Clut43 dis4 diameter F > "le4troni4 Catalogue o= Original Parts


Identi


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1


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O2er2iew o= Transmission SEstem

!esignation

*ote

-(rrows- in direction of tra,el

1 - Engine

2 - Clutch

- &anual gearbox

/ - !ri,e shaft

3 - 4utput shaft

$ - !ifferential gear

-(rrows- in direction of tra,el

11


12/167

I - 1st gear

II - 2nd gear

III - rd gear

I5 - /th gear

5 - 3th gear

6 - 6e,erse gear

( - 7inal dri,e

+ - 8peedometer dri,e

&eneral repair in=ormation

To 4arrE out gearbox repairs su44ess=ullE and 4orre4tlE? s4rupulous 4are and 4leanliness? as

well as t3e proper tools? are essential re:uirements* Ob2iouslE? t3e generallE 2alid basi4sa=etE rules applE to repair wor*

A number o= generallE 2alid notes =or indi2idual repair operations w3i43 are ot3erwise listed

1!


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se2eral times at numerous points in t3e wors3op manual are summariHed 3ere*

&earbox

t,3en installing? ensure t3e dowel slee2es are 4orre4tlE lo4ated between t3e engine and

gearbox*

t ,3en repla4ing t3e gearbox 43e4 t3e oil le2el and i= ne4essarE top up> C3apter*

t $illing 4apa4itE > C3apter*

t Spe4i ele4troni4 4atalogue o= original parts*

Orings? gaset rings? gasets? sealant

On gearboxes wit3 paper gasets

t 'epla4e paper gasets*

On gearboxes wit3 sealants

T3oroug3lE 4lean t3e 3ousing 4onta4t sur=a4es be=ore applEing t3e sealant*

ApplE sealant AMV 1 ! / e2enlE and not too t3i4lE*

AlwaEs repla4e Orings? gaset rings and gasets*

A=ter remo2ing gasets? 43e4 t3e 4onta4t sur=a4e on t3e 3ousing or s3a=t =or burrs or

damage w3i43 o44ured during t3e disassemblE*

.ig3tlE oil radial s3a=t seals at outside

diameter be=ore mounting and C3apter*

Cir4lips and tensioning slee2es

Do not o2ertension t3e 4ir4lips*

AlwaEs repla4e damaged or o2ertensioned4ir4lips*

Cir4lips must be positioned in t3e base o=

1/

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43152http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44400http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45648http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56096http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43152http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44400http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45648http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56096


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t3e groo2e*

'epla4e roll pins* $itting position Slot A

longitudinal to power Gow arrow*

S4rews? nuts

t Sla4en t3e bolts and nuts against t3etig3tening se:uen4e*

t

Sla4en and tig3ten nuts and bolts =or

atta43ing 4o2ers and 3ousings wit3out

tig3tening se:uen4e diagonallE a4ross in

stages*

t

Do not twist parti4ularlE sensiti2e parts

e*g* 4lut43 pressure plates and sla4en

and tig3ten diagonallE a4ross in stages*

t Tig3tening tor:ues applE =or nonoiled

nuts and bolts*

tAlwaEs repla4e t3e sel=lo4ing nuts and

s4rews*

t

Clean t3e t3read o= t3e s4rews t3at are

inserted wit3 a lo4ing agent wit3 a wire

brus3* Insert bolts wit3 lo4ing agent

AMV 15 11 A1*

t T3e t3readed 3oles into w3i43 sel=lo4ing

s4rews or s4rews wit3 lo4ing agent were

s4rewed in 7e*g* wit3 a s4rewtap8 must

1+


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be 4leaned* Ot3erwise t3ere is a ris t3at

t3e s4rews will s3ear at t3e next

disassemblE*

(earings

tPosition needle bearing wit3 t3e lettered

side 7t3i4er end8 towards t3e dri=t pin*

t$it all bearings to t3e gearbox wit3 some

gearbox Guid*

t

ointlE repla4e taperedroller bearings on

t3e same s3a=t and use produ4ts o= t3e

same manu=a4turer*

t

(e=ore installing? 3eat t3e inner rings o=

t3e taperedroller bearings on a 3eating

plate or wit3 t3e indu4tion 3eater unit?

e*g* VAS 6+1+? to approx* 1JC* ,3enassembling? press up to t3e stop until

t3ere is no axial plaE*

t

Do not ex43ange t3e outer and inner

rings o= bearings o= t3e same siHe

bearings go in pairs*

S3ims

t

&auge s3ims at se2eral points wit3 a

mi4rometer* Dierent toleran4es allow tomeasure t3e re:uired t3i4ness =or ea43

was3er 2erE pre4iselE*

t Inspe4t =or burrs and damage*

tInstall onlE s3ims w3i43 are in per=e4t

4ondition*

SEn43roniHer rings

t

T3ese are not inter43angeable* I= re

using? allo4ate sEn43roniHer rings to t3e

same gear*

tInspe4t =or wear? repla4e i= ne4essarE

> "le4troni4 Catalogue o= Original Parts*

t Insert wit3 some gearbox Guid*

&ear pinions and sEn43roniHer bodE

t

Clean and 3eat on a 3eating plate or wit3

t3e indu4tion 3eater unit e*g* VAS 6+1+to approx* 1JC be=ore pressing on*

t ,3en assembling? press up to t3e stop

15

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp72160http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp72160


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until t3ere is no axial plaE*

t C3e4 C3apter8*

t

In order to redu4e unpleasant odours i=

t3e 4lut43 is burnt? t3oroug3lE 4lean t3e

4lut43 3ousing as well as t3e GEw3eel and

t3e engine on t3e side o= t3e gearbox*

16

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp78768http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp78768


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Clut43? 4ontrol

'epairing 4lut43 4ontrol

O2er2iew

#ote

tI= t3e master or sla2e 4Elinder s3ould be repla4ed due to a suspe4ted de=e4t? C3apter*

tI= t3e batterE eart3 strap is dis4onne4ted and 4onne4ted? 4arrE out additional operations

> "le4tri4al SEstem > 'ep* &r*!9*

t On models (odE

,or > 'ep* &r*9*

I SummarE o= 4omponents $oot 4ontrols > C3apter

19

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38096http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39456http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp39840http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp42528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44432http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38096http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39456http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp39840http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp42528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44432


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II SummarE o= 4omponents %Edrauli4s > C3apter

SummarE o= 4omponents $oot 4ontrols

1 (ul3ead

: wit3 mount =or bra4et and master 4Elinder

! &aset

: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts

/ (ra4et

: =or support o= 4lut43 pedal

+ S4rew

1

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45936http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp38864http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45936http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp38864


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5 (ra4et

: =or support o= a44elerator pedal and brae pedal

6 !5 #m

: sel=lo4ing


9 Conne4ting plate

!5 #m

: sel=lo4ing


; (us3ing

1 (earing bolt

11 Clut43 pedal

: remo2ing and installing > C3apter

1! Support


1/ !5 #m

: sel=lo4ing


1+ Master 4Elinder


15 Tubing

16 O2er4entre 3elper spring


19 (earingBo2er3elper 4entre spring

: insert in bra4et

: to repla4e? remo2e and install t3e master 4Elinder > C3apter

1 Clut43 pedal swit43 $/6


1; .imit stop Eoe

: =or t3e 4lut43 pedal

: $itting position > C3apter

1;

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp41808http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43472http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45264http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46768http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp48528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49552http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp51440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp53200http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55216http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56976http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp41808http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43472http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45264http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46768http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp48528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49552http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp51440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp53200http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55216http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56976


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! !5 #m

: sel=lo4ing


'emo2ing and installing t3e o2er4entre 3elper spring

Spe4ial tools and wors3op e:uipment re:uired

t AssemblE 4lamps //19

'emo2ing

'emo2e t3e bottom le=t storage area on t3e dri2erLs side > (odE ,or > 'ep* &r*9*

0sing t3e 4lut43 pedal stret43 t3e o2er

4entre 3elper spring and w3ile doing so

pus3 down t3e assemblE 4lamp //19

=rom abo2e*

#ote

T3e bore 3ole arrow points towards t3e

4lut43 pedal*

Position t3e 4lut43 pedal in 3ome position

and remo2e t3e o2er4entre 3elper spring

toget3er wit3 assemblE 4lamp //19

Install

Put t3e 4lut43 pedal in 3ome position*

$irst position t3e o2er4entre 3elper

spring in t3e o2er4entre 3elper spring

bearing (? t3en press t3e 4lut43 pedal

down until t3e 4entering pin o= t3e 4lut43

pedal A tou43es t3e o2er4entre 3elper

spring*

0sing t3e 4lut43 pedal stret43 t3e o2er

4entre 3elper spring? w3ile doing so

remo2e t3e assemblE 4lamp //19*

!

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp58736http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp39728http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp58736http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp39728


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'emo2ing and installing t3e 4lut43 pedal

'emo2ing

'emo2e t3e bottom le=t storage area on t3e dri2erLs side > (odE ,or > 'ep* &r*9*

'emo2e 4lut43 pedal swit43 $/6 7i= present8 > C3apter*

'emo2ing t3e o2er4entre 3elper spring > C3apter*

Separate t3e 4lut43 pedal =rom t3e master 4Elinder > C3apter*

0ns4rew t3e nut A and pull s4rew out o=

t3e bra4et*

'emo2e 4lut43 pedal*

Install

Installation is per=ormed in t3e re2erse

order? paE attention to t3e =ollowing points

T3e support A must

be lo4ated on t3e

a4tuating rod ( o=

t3e master 4Elinder*

Press t3e 4lut43

pedal until its lo4s

in dire4tion o=

arrow and mae

sure it 4at43es

4orre4tlE*

Installing t3e o2er

4entre 3elper spring

> C3apter*

I= present? install

4lut43 pedal swit43

$/6 > C3apter*

Tig3tening tor:ue

Component #m

!1

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp37952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp38336http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp40368http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp52272http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp37952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp38336http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp40368http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp52272


22/167

Clut43 pedal to bra4et !518

18 AlwaEs repla4e nut > "le4troni4 Catalogue o= Original Parts

'emo2ing and installing 4lut43 pedal swit43 $/6

*ote

+he clutch pedal switch ma% onl% be installed once to ensure that it has an ade9uatel% tight fit)

'emo2ing and installing t3e 4lut43 pedal swit43 $/6 7angular 3ousing8

;ress down clutch pedal up to the stop b% hand)

+urn clutch pedal switch '0< to the left and

remo,e from its bracet=clutch pedal -arrows-)

;ress down clutch pedal up to the stop b%

hand)

Insert clutch pedal switch into the assembl%

opening)

+hen turn the switch '0< to the right for

securing)

;ut the clutch pedal in home position)

+he clutch pedal must be in end position)

'emo2ing and installing t3e 4lut43 pedal swit43 $/6 7round 3ousing8

+urn clutch pedal switch /3< to the left and remo,e from the bracet=clutch pedal)

;ull out the tappet -arrow- completel% before

assembl% of the clutch pedal switch)

Insert the switch with the catch pegs -1- and -2-

in the recesses pro,ided for it in the assembl%

opening and attach b% turning it /3< to the right)

l+he clutch pedal must be put into home position

do not depress)

l+he clutch pedal must not be operated when

installing it)

l

+he plunger is ad>usted automaticall% when

inserting the clutch pedal switch)

!!



23/167

SummarE o= 4omponents %Edrauli4s

1 (rae Guid reser2oir

! Tubing

/ Master 4Elinder


+ Support

onlE repla4e i= t3e master 4Elinder 3as been remo2ed

remo2ing > $ig*

installing > $ig*

5 Clut43 pedal


6 !5 #m

: sel=lo4ing

!/

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38992http://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/clutch_control/repairing_clutch_control/summary_of_components_hydraulics/#xys-twe348roemhttp://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/clutch_control/repairing_clutch_control/summary_of_components_hydraulics/#xls-twedcroemhttp://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44096http://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/clutch_control/repairing_clutch_control/summary_of_components_hydraulics/#xys-twe348roemhttp://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/clutch_control/repairing_clutch_control/summary_of_components_hydraulics/#xls-twedcroemhttp://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38992http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44096


24/167


9 Support

: Mounted at t3e stru4ture

'elease s3a=t


; Sla2e 4Elinder


1 Collar s4rew? !5 #m

11 Support

: =or tube3ose line pos* 1!

1! Tube3ose line

: assign a44ording to > "le4troni4 Catalogue o= Original Parts

1/ Pipe 4onne4tionBplug 4onne4tion

1+ Dust 4ap

15 (leed 2al2e

: (leed t3e 4lut43 sEstem > C3apter

16 Oring

: pull onto line 4onne4tion

: insert wit3 brae Guid

19 Clamp

1 &earbox

!+

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp47520http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49024http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp51552http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp53344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp47520http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49024http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp51552http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp53344


25/167

.i=t o t3e support A in t3e dire4tion o=

t3e arrow*

Pus3 t3e a4tuator rodBmaster 4Elinder in

t3e support A in dire4tion o= t3e arrow*

C3e4 3Edrauli4 4lut43 4ontrol

l T3e pedal a4tuation must not be obstru4ted bE mo2ed or additional =oot mats*

l (leed t3e 4lut43 sEstem i= ne4essarE > C3apter*

!5



26/167

$irst o= all 43e4 t3e brae Guid le2el in

t3e brae Guid reser2oir*

#ote

t

T3e 4lut43 3Edrauli4 is 4onne4ted to one

o= t3e 43ambers arrow ! o= t3e braeGuid reser2oir bE t3e return 3ose arrow

1*

tI= t3ere is no or little brae Guid in t3is

43amber? t3ere is a lea in t3e sEstem*

Subse:uentlE 43e4 t3e =ollowing

4omponents o= t3e 3Edrauli4 4lut43

4ontrol =or external lea

t'eturn 3ose between brae Guid reser2oir

and master 4Elinder

t Master 4Elinder

t Tube3ose line between master and sla2e

4Elinder

tConne4tion points 7plug and s4rew

4onne4tions8 also in a non2isible area

t Sla2e 4Elinder

#ote

t

SEmptoms o= an external lea are?

amongst ot3ers? tra4es o= brae Guid on

or below t3e gearbox? as well as on t3e

noise insulation under t3e gearbox*

t

C3e4 t3e 4orre4t routing o= t3e tube

3ose line between t3e master and sla2e

4Elinder* T3e line must not be ined or

trapped*

Subse:uentlE depress t3e 4lut43 pedal

4are=ullE? at t3e same time 3old t3e pedal

in An43or* At t3esame time t3e


27/167

w3ile being 3eld*

'emo2e t3e sla2e 4Elinder =rom t3e

gearbox last? do not open t3e linesEstem and 43e4 t3e 4ollar =or brae

Guid lea*

To t3is end tae o t3e 4ollar =rom t3e

tappet arrow*

'emo2ing and installing t3e master 4Elinder


t %ose 4lamps up to !5 mm MP96! 7/;+8

t Pliers T15

'emo2ing

#ote

tI= t3e master 4Elinder must be repla4ed? C3apter*

t 0ns4rew t3e master 4Elinder =rom wit3in t3e passenger 4ompartment*

t

,3en per=orming t3e =ollowing wor? mae sure t3at no brae Guid 4omes into 4onta4t wit3

t3e =rame side rail or t3e gearbox* I= t3is is t3e 4ase? t3ese points must be 4leaned

t3oroug3lE*

'emo2e air "ngine > 'ep* &r*!/ or > "ngine > 'ep* &r*!+*

I= ne4essarE? remo2e A(S 4ontrol unit wit3 3Edrauli4 unit > C3assis > 'ep* &r*+5*

!9

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp40848http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43056http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp43440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp44208http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44592http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp46240http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp40848http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43056http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp43440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp44208http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44592http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp46240


28/167

Dis4onne4t t3e return 3ose A to t3e

brae Guid reser2oir wit3 t3e 3ose 4lamp

MP96! 7/;+8 and deta43*

Pull 4lamp ( out o= t3e master 4Elinder*

'elease and 4ut o t3e tube3ose line C

=rom t3e master 4Elinder*

'emo2e t3e bottom le=t storage area on

t3e dri2erLs side > (odE ,or > 'ep*

&r*9*

'emo2e 4lut43 pedal swit43 $/6 7i=

present8 > C3apter*

#ote

To remo2e t3e master 4Elinder 4ompletelE

remo2e t3e 4lut43 4ontrol* (e=ore remo2ing


29/167

0ns4rew nuts arrows 1 and remo2e

4onne4ting plate arrow A*

0ns4rew t3e nuts arrows ! and remo2e

t3e 4lut43 4ontrols arrow ( toget3er

wit3 t3e master 4Elinder*

Turn 4lut43 pedal stop A in dire4tion o=

arrow and remo2e*

!;


30/167

T3en press t3e master 4Elinder up to t3e

stop in dire4tion o= arrow 1*

It must not be 4o2ered in t3e upper area

=rom t3e bearing =or o2er4entre 3elper

spring arrow !*

T3en swi2el t3e master 4Elinder in

dire4tion o= arrow / out o= t3e bra4et*

Install



T3e support A must

be lo4ated on t3e

a4tuating rod ( o=

t3e master 4Elinder*

Press t3e 4lut43

pedal until its lo4s

in dire4tion o=

arrow and mae

sure it 4at43es

4orre4tlE*

/


31/167


32/167

Pull t3e tube3ose line out o= t3e 3older

on t3e sla2e 4Elinder*

Subse:uentlE release t3e s4rews arrows

and remo2e t3e sla2e 4Elinder =rom t3e

release s3a=t o= t3e gearbox*

Pin43 o t3e tube3ose line to t3e sla2e

4Elinder wit3 t3e 3ose 4lamp MP96!7/;+8*

Pull out t3e 4lamp > Item and

subse:uentlE t3e tube3ose line =rom t3e

sla2e 4Elinder* Close t3e line*

Install



Press t3e 4lamp > Item into t3e sla2e

4Elinder up to t3e stop*

Pus3 t3e tube3ose line into t3e sla2e

4Elinder until it 4an be 3eard to engage*

&rease tappet end wit3 grease =or plug

serration o= 4lut43 dis4 & 1*

Insert t3e sla2e 4Elinder in t3e release

s3a=t and s4rew it onto t3e gearbox*

A=ter installing t3e sla2e 4Elinder bleed

t3e 4lut43 sEstem > C3apter*

Install noise insulation below

engineBgearbox*

Tig3tening tor:ue

Sla2e 4Elinder to gearbox !5 #m

(leeding t3e 4lut43 sEstemSpe4ial tools and wors3op e:uipment re:uired

#ote

t ,3en per=orming t3e =ollowing wor? mae sure no brae Guid 4omes into 4onta4t wit3 t3e

/!

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp42928http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45360http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49264http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp42928http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45360http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49264


33/167

gearbox*

t $irst open t3e bleeder 2al2e be=ore swit43ing on t3e bleeding de2i4e*

t A pre


34/167

'epairing 4lut43

$ault C3apter*

(e=ore ea43 4lut43 repair? examine and re4onstru4t t3e 4omplaint o= t3e 4ustomer* In ea43

indi2idual 4ase? it must be determined i= indeed t3ere are problems wit3 t3e 4lut43 or t3e

in4orre4t setting o= t3e gears3i=t is 4ause =or 4omplaint*

$ault $ault tEpe Measure

Clut43 pedal does not

return to initial

position*

t Air in line sEstem*

Vent air =rom t3e line sEstemQ top up

wit3 brae Guid*

t

.ine sEstem? master

4Elinder or sla2e 4Elinder

leaing*

'epla4e de=e4ti2e 4omponent? 2ent air

=rom t3e line sEstemQ top up wit3 brae

Guid*

t

Membrane spring o= t3e

pressure plate broen*

'epla4e pressure plate*


A4tuating =or4e

on t3e 4lut43

pedal too 3ig3*

tO2er4entre 3elper

spring de=e4ti2e*

'epla4e o2er4entre 3elper spring*

t

Clut43 release =or4e

in4reased due to

wear o= 4lut43

linings*

In=orm 4ustomer 73ig3er release =or4e wit3

in4reased wear8*

'epla4e 4lut43 dis4? w3en t3e distan4e baseBri2et is

below *1 mm*

t

Pressure plate wit3

wrong spring

identi "le4troni4

Catalogue o= Original Parts*

t

Me43ani4al =ault at

t3e pressure plate or

t3e 4lut43 dis4*

'epla4e de=e4ti2e parts*

t

Clut43 dis4 on t3e

serrationsluggis3BRams*

C3e4 serration o= t3e 3ub =or damage 7burrs8*

'epla4e t3e 4lut43 dis4 i= ne4essarE*

Clean t3e 3ub and t3e dri2e s3a=t serration =rom

4orrosion and residues o= lubri4ant and grease wit3

/+

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38048http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp83104http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp83104http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38048http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp83104http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp83104


35/167

grease =or plug serration o= 4lut43 dis4 & 1 *

Mo2e 4lut43 dis4 ba4 and =ort3? remo2e ex4ess

grease*

t

Clut43 pus3 rod and

release plate

7pressure plate8

sluggis3*

.ig3tlE grease 4onta4t points wit3 grease =or plug

serration o= 4lut43 dis4 & 1*

.ig3tlE grease 4lut43 pus3 rod*


Clut43

4ontrol

noises*

t'elease bearing

de=e4ti2e*

'epla4e release bearing*

t

Centre displa4ement o=

engineBgearbox*

C3e4 dowel slee2es*

t

Clut43 dis in4orre4tlE

mounted*

Corre4t t3e "le4troni4 Catalogue o= Original Parts

=or t3e assignment o= t3e 4lut43 dis4*


S4rat43 noises w3en t3e

=orward or re2erse gear is

engaged? gears43i=t Rams?

3oos? is sluggis3? s3i=ting

not possible? 4lut43 wit3out

operation*

tAir in t3e sEstem? 4lut43

does not separate =ullE*

C3e4 and bleed sEstem? top

up wit3 brae Guid*

t

Master 4Elinder or sla2e

4Elinder is leaing? line is

leaing*

'epla4e de=e4ti2e 4omponent?

top up wit3 brae Guid? 2ent air

=rom t3e sEstem*

t

T3e tra2el o= t3e 4lut43

pedal is not su4ent

74arpet? =oot mat under t3e

pedal8? pedal is not =ullE

depressed*

In=orm 4ustomer*

t Pressure plate une2en due

to in4orre4t installation?

4lut43 dis4 warped due to

C3e4 4omponents? i=

ne4essarE repla4e? mae sure

t3e 4entering pins are 4orre4tlE

/5



36/167

improper 3andling* "le4troni4 Catalogue

o= Original Parts =or t3e

assignment o= t3e 4lut43 dis4*

t

.ining glued to t3e GEw3eel

7long immobiliHation time?

3ig3 3umiditE8*

Slig3tlE rub down t3e =ri4tion

sur=a4es o= t3e 4lut43 lining? i=

ne4essarE w3en 4orrosion

o44urs in a larger area? repla4e

t3e 4omponent 4ompletelE*

t

Clut43 dis4 on t3e serration

sluggis3BRams* Corroded 3ub?

damaged during assemblE*

%ub pro


37/167

t

,3en starting? linings are

spalled o t3roug3 slipping

=or too long a time*

t

Clut43 pus3 rod too s3ort

due to wear*

'epla4e 4lut43 pus3 rod* C3e4

release bearing? repla4e i=

ne4essarE*

.ig3tlE grease 4onta4t points o=

4lut43 pus3 rod to release

bearing wit3 grease =or plug

serration o= 4lut43 dis4

& 1 *


.oad alteration s3o4s w3en

pus3ing t3e a44elerator pedal

down s3arplE and w3en t3e

engine speed drops suddenlE*

tAssemblE bra4et is

too so=t*

In=orm 4ustomer* 0se t3e

> "le4troni4 Catalogue o=

Original Parts =or t3e

assignment o= t3e 3anger*

t

Irregular engine

running*

C3e4 engine setting? 4orre4t*

t

Clut43 dis4 wit3

predamper is built inagainst gear rattling*

In=orm 4ustomer*

t

Centre displa4ement o=

engineBgearbox*

Test dowel slee2es? repla4e i=

ne4essarE*


Clut43 slips?

no or poor

a44eleration

t,rong 4lut43 dis4 "le4troni4

Catalogue o= Original Parts

=or t3e assignment o= t3e

4lut43 dis4 and t3e pressure

plate*

t

Clut43 dis4 worn out? burnt? pressure plate

o2er3eated? s4oring? pressure plate warped

t3roug3 in4orre4t assemblE? 4onta4t pressure

o= t3e pressure plate too low? dri2ing error?natural wear*

'epla4e 4lut43 dis4*


In=orm 4ustomer*

t Clut43 dis4? pressure plate? GEw3eel oilE*

/9

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp197952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp197952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp224736http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp224736http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp197952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp197952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp224736http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp224736


38/167

S3a=t seal o= t3e engine or t3e gearbox

de=e4ti2e* &rease on t3e 4onta4t sur=a4e

t3roug3 ex4ess greasing o= t3e 3ub*

t Clut43 dis in4orre4tlE mounted*

Corre4t t3e "le4troni4 Catalogue o= Original

Parts =or t3e assignment o= t3e assemblE

bra4et*

t

Clut43 lining oilE? 4onta4t sur=a4e o=

pressure plate and GEw3eel oilE 7oil

leaage =rom t3e 4lut43 3ousing8*

C3e4 s3a=t seal o= t3e dri2e s3a=t =or

4lut43 or 43e4 4rans3a=t? i= ne4essarE

repla4e*

'epla4e 4lut43 dis4? 4lean pressure plate

and GEw3eel*

t

Dri2e s43a=t too 3ea2ilE greased

7tra4es o= grease on t3e 4lut43 dis4?

pressure plate and GEw3eel8*

Clean pressure plate and GEw3eel =ree o=

grease? repla4e in t3e e2ent o= damage

7tra4es o= wear? o2er3eating? groo2es8*

'emo2e tra4es o= grease =rom 3ub and

s3a=t? grease s3a=t lig3tlE wit3 grease =or

/

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp274144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp274144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp278656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp278656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp274144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp274144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp278656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp278656


39/167

plug serration o= 4lut43 dis4 & 1*

Mo2e 4lut43 dis4 ba4 and =ort3? remo2e

ex4ess grease*


A4ousti4 load alteration

s3o4 4li4ing w3en

4oupling 7release 4lut43

pedal8*

t

Carrier eart3Bdri2e s3a=t is a44elerated wit3 sudden

4oupling* T3e dri2e s3a=t serration o= t3e pinions in

mes3 no4sQ =or 4lut43 dis4s wit3 predamper t3e

noise in4reases as t3e predamper rea43es t3e stop*

In=orm

4ustomer*


#oises

in idle*

t Torsional damper spring broen* 'epla4e 4lut43 dis4*

t

Clut43 dis4 "le4troni4 Catalogue o=

Original Parts =or t3e assignment o= t3e

4lut43 dis4*

t

Pressure plate warped? broen?

imbalan4e*


t Irregular engine running*

C3e4 engine setting? 4orre4t i=

ne4essarE*

t

T3e displa4ement o= t3e engine to t3e

gearbox is too large 7dowel slee2es are

missing8*

(e=ore installing t3e gearbox? insert t3e

dowel slee2es*

t Intermediate plate rubs on t3e GEw3eel*

Insert intermediate plate on sealing

Gange and pus3 onto t3e dowel slee2es*

SummarE o= 4omponents repairing t3e 4lut43


t &rease =or t3e plug serration o= t3e 4lut43 dis4 & 1

#ote

t (e=ore repla4ing t3e 4lut43 dis4 and pressure plate =ault


40/167

obser2e 4omplaints o= t3e 4lut43 and 4lut43 4ontrol > C3apter*

tI= t3e dowel slee2es are not present? t3is 4an result in di4ulties to s3i=t? 4lut43 problems

and i= ne4essarE noises =rom gearbox 7gear rattling8*

t 'epla4e t3e 4lut43 dis4s and pressure plates i= t3e ri2eting is damaged or loose*

tAssign t3e 4lut43 dis4 and t3e pressure plate a44ording to t3e > "le4troni4 4atalogue o=

original parts and engine identi


41/167

: T3e lo4ating =a4e =or t3e 4lut43 lining must be =ree =rom groo2es? oil and grease

:

T3e insertion dept3 o= t3e TDC sender must be adapted to t3e 2arious siHes o= t3e

GEw3eels* T3ere=ore two s4rew plugs in t3e 4lut43 3ousing mared in dierent 4olours*

Assignment > C3apter

/ Clut43 dis4

: 4enter > C3apter

: Diameter > "le4troni4 Catalogue o= Original Parts

+ Clut43 pus3 rod

: grease in t3e area o= t3e bearing bus3ing in t3e dri2e s3a=t

5 'etaining loop

6 'elease plate

: ApplE a 2erE t3in laEer o= grease =or plug serration o= 4lut43 dis4 & 1 to t3e 4onta4tsur=a4e and support =or t3e 4lut43 pus3 rod*

9 $ixing s4rew o= pressure plate at 4rans3a=t

: remo2ing and installing > "ngine > 'ep* &r*1/

Intermediate plate

: $itting position > C3apter

; Pressure plate


: Distortion o= t3e inner pressure plate max* *! mm

: 'epla4e t3e pressure plate i= t3e ri2eting is damaged or loose

'emo2ing and installing 4lut43



t Counter3older MP1!!1 7V, 558

t .o4ating dis4 T1!6

t Centering de2i4e MP!+

'emo2ing

'emo2ing t3e gearbox > C3apter*

+1

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46688http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48256http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49504http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp53520http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp53936http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55312http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56992http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41616http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46688http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48256http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49504http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp53520http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp53936http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55312http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56992http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41616


42/167

'emo2e GEw3eel? to do so lo4 wit3

4ounter3older MP1!!1 7V, 558*

'emo2e 4lut43 dis4*

.e2er and remo2e t3e retaining ring A

=or t3e release plate ( out o= t3e 3oles

using a s4rewdri2er arrows*

'emo2e release plate (*

0ns4rew pressure plate? to t3is end lo4

4ounter 3older MP1!!1 7V, 558 at

pressure plate wit3 s4rew A*

'emo2e pressure plate and intermediateplate*

Install

Position pressure plate*

$it t3e intermediate plate*

+!


43/167

$itting lo4ation o= intermediate plate T3e

raised part arrow points awaE =rom t3e

pressure plate*

#ote

Insert new


44/167

On 4ertain 2e3i4les t3e pre2ious 4entering

de2i4e MP!+ 7/198 4an also be used*

.o4 GEw3eel =or tig3tening t3e C3apter*

++



45/167

&earbox me43ani4s?operation? 4onstru4tion?di*

'epairing t3e gears3i=t me43anism

$itting lo4ation o= s3i=t me43anism

T3e 4oupling rod C ser2es as 4ountersupport =or t3e sele4tor mo2ements

Double arrow A s3i=t mo2ement

Double arrow ( sele4tor mo2ement

A &ear s3i=t rods =or s3i=t mo2ement

( Coupling rods =or sele4tor mo2ement

+5


46/167

#ote

t On models "le4tri4al SEstem > 'ep* &r*!9*

t,3en t3e batterE is re4onne4ted? paE attention to t3e wor a=ter 4onne4ting t3e batterE


t &rease all bearing and 4onta4t sur=a4es wit3 grease & +5 !*

I SummarE o= 4omponents s3i=t 3ousing B s3i=t le2er > C3apter

II SummarE o= 4omponents re2erses3i=t me43anism at t3e gearbox > C3apter

'emo2ing and installing s3i=t 3ousing > C3apter*

Setting t3e s3i=t me43anism > C3apter*

+6

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42864http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp43248http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp44384http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44768http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48000http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49728http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp51264http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp52928http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42864http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp43248http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp44384http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44768http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48000http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49728http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp51264http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp52928


47/167


48/167

: onlE =or 2e3i4les $ig*

5 Open warmtEpe 4lamp

: =or se4uring t3e gears3i=t nob to t3e gears3i=t le2er

: open > $ig*


: atta43 wit3 3ose binding 4law V*A*& 1!95 onto t3e gears3i=t nob

6 S3i=t le2er

: remo2ing and installing =rom s3i=t 3ousing > C3apter

9 Spa4er bus3

Collar s4rew? !5 #m

; S3i=t 3ousing


1 &ear s3i=t rod


: a=ter installing set s3i=t me43anism > C3apter

11 ! #m

1! !5 #m

1/ Pressure spring

1+ Stop

: a=ter installing set s3i=t me43anism > C3apter

15 !5 #m

: Coat t3read wit3 lo4ing agent D 6 A!

16 (all so4et

: remo2ing > C3apter

19 (us3ing

1 S3o4 absorber

1; 15 #m

+

http://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/gearbox_mechanicsoperation_constructiondiff./repairing_the_gearshift_mechanism/summary_of_components_shift_housing/shift_lever/#x-6gu1cuagrthttp://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/gearbox_mechanicsoperation_constructiondiff./repairing_the_gearshift_mechanism/summary_of_components_shift_housing/shift_lever/#x-qbxfyus7embhttp://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp52960http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp57856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp59536http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp60800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp63728http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp66800http://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/gearbox_mechanicsoperation_constructiondiff./repairing_the_gearshift_mechanism/summary_of_components_shift_housing/shift_lever/#x-6gu1cuagrthttp://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/gearbox_mechanicsoperation_constructiondiff./repairing_the_gearshift_mechanism/summary_of_components_shift_housing/shift_lever/#x-qbxfyus7embhttp://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp52960http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp57856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp59536http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp60800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp63728http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp66800


49/167

'emo2e gears3i=t nob and 4ollar

Pull out t3e 4ollar =or t3e s3i=t le2er

towards t3e top arrows*

Open warmtEpe 4lamp

Open t3e open warmtEpe 4lamp arrow

and pull o gears3i=t nob toget3er wit3

t3e 4ollar*

+;


50/167

Separate gears3i=t nob =rom 4ollar and

assemble wit3 4ollar

Turn 4ollar inside out*

.e2er o 4lamping slee2e arrow wit3

s4rewdri2er*

Deta43 4lamping slee2e =rom s3i=t le2er*

Turn gears3i=t nob inside out and deta43

=rom 4ollar*

Install

Turn 4ollar inside out*

Insert gears3i=t nob into 4ollar*

Pus3 4lamping slee2e o2er gears3i=t

nob and 4ollar*

Press toget3er 4lamping slee2e until it

4li4s into pla4e*

'emo2ing and installing s3i=t 3ousing wit3 s3i=t le2er and s3i=t rod


t %ose binding 4law V*A*& 1!95

'emo2ing

5


51/167

Pull out t3e 4ollar =or t3e s3i=t le2er

towards t3e top arrows*

Pull t3e 4ollar upwards o2er t3e gears3i=t

nob*

Open t3e open warmtEpe 4lamp arrow

and pull o gears3i=t nob toget3er wit3

t3e 4ollar*

'emo2e sound absorption > Item? i=

present*

51



52/167

'elease


53/167

.oosen warmtEpe 4lamp arrow*

Separate t3e 4onne4tion o= t3e s3i=t

rodBsele4tor le2er*

'elease bot3 lower "ngine

> 'ep* &r*!6*

Cross member to bodE > "ngine > 'ep*

&r*!6*

Setting t3e s3i=t me43anism > C3apter*

Atta43 new warmtEpe 4lamp arrow

wit3 3ose binding 4law V*A*& 1!95 onto

t3e gears3i=t nob*

Tig3tening tor:ues

S3i=t 3ousing to bodE

s4rew M

!5 #m

S3i=t 3ousing to bodE

nut M

!5 #m

S3i=t rod to sele4tor le2er !5 #m

5/

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp53328http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp53744http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp55152http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp55568http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp55568http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56944http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp53328http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp53744http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp53744http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp55152http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp55568http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp55568http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56944


54/167

'emo2ing and installing s3i=t le2er =rom s3i=t 3ousing

'emo2ing

'emo2e s3i=t 3ousing > C3apter*

'elease s4rew arrow and remo2e s3i=t

rod =rom s3i=t le2er*

0ns4rew s4rew 1 and remo2e bus3ing

! wit3 s3o4 absorber /*

0ns4rew s4rews arrows =or stop +*

5+



55/167

Press in 3oos o= t3e 76 pie4es8 ball

so4et arrows using a s4rewdri2er and

4are=ullE pull s3i=t le2er out o= t3e s3i=t

3ousing towards t3e top*

Press o ball so4et in dire4tion o=arrow =rom t3e s3i=t le2er*

Installing

Installation is 4arried out in t3e re2erse

order*

#ote

t Install s3i=t 3ousing > C3apter*

t Setting t3e s3i=t me43anism > C3apter*

Tig3tening tor:ues

S3i=t rod to s3i=t le2er ! #m

Stop =or s3i=t le2er to s3i=t 3ousing !5 #m

SummarE o= 4omponents re2erses3i=t me43anism at t3e gearbox

#ote

&rease bearing and =ri4tion sur=a4es wit3 grease & +5 !*

55

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49168http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50560http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49168http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50560


56/167

1 ! #m

: sel=lo4ing


: S3i=t le2er on gearbox

! &earbox s3i=t le2er

: onlE


57/167

: Installation o= t3e new 4onsole on t3e gearbox up to 9*; > $ig*

9 Coupling rod

S3i=t rod wit3 balan4ing weig3t

; S3ield

: is


58/167


59/167

+ (allQ press o using a s4rewdri2erQ press

out up to t3e stop

5 (ra4et

6 'e2ersing le2er

Setting t3e s3i=t me43anism


t S3i=t le2er gauge /+!1

#ote

t T3e =ollowing are re:uired =or 4orre4t setting o= t3e s3i=t me43anism

t Operating and transmission elements o= t3e s3i=t me43anism are in per=e4t 4ondition*

t S3i=t me43anism operates =reelE*

t &earbox? 4lut43 and 4lut43 4ontrol must be in per=e4t 4ondition*

l &earbox in #eutral*

'emo2e gears3i=t nob wit3 4ollar > C3apter*

.oosen warmtEpe 4lamp arrow* T3e

s3i=t rodBsele4tor le2er s3ould mo2e

=reelE*

5;



60/167


61/167

Tig3ten nut arrow =or warmtEpe 4lamp

to ! #m and tae out s3i=t le2er gauge

/+!1*

Install bus3ing =or s3i=t le2er > C3apter*

Depress 4lut43*

"ngage re2erse gear*

'elease s4rew 1*

#ote

T3en press down t3e le=t side o= t3e stop

dire4tion o= arrow*

Tig3ten s4rews1 and ! to !5 #m*

Tae out re2erse gear*

Depress 4lut43*

S3i=t t3roug3 all gears se2eral times* PaE

parti4ular attention to proper operation

o= t3e re2erse gear lo4*

I= a gear 4at43es w3en repeatedlE

engaging? pro4eed as =ollows

"ngage 1st gear*

"liminate t3e plaE in t3e s3i=t me43anism

bE 4are=ullE pressing t3e s3i=t le2er to t3ele=t*

61



62/167


63/167

> C3apter*

'emo2ing and installing t3e gearbox


t Alignment rails MP/+59 7V, +598 743ange > An43or8

t Supporting de2i4e =or engine MP/+9 7// A8

t &earbox atta43ment de2i4e MP/+9 7///68

t Supporting de2i4e MP;! 71!!!A8

t &earbox mount /!!

t AdRusting plate /!!B5


t %exagon s4rew M x !5

C3ange alignment rail MP/+59 7V, +598

T3e alignment rail MP/+59 7V, +598 is re:uired w3en remo2ing and installing t3e

gearbox*

An additional 3ole arrow is ne4essarE =or

atta43ing t3e alignment rail MP/+59 7V,

+598 to t3e assemblE 4arrier*

Dimensions in mm*

I= t3is 3ole is not Eet present? a 3ole o=

*5 mm F arrow must be drilled into t3e

alignment rail MP/+59 7V, +598*

'emo2ing t3e gearbox

#ote

be


64/167

Dis4onne4t t3e eart3 strap =rom t3e batterE wit3 t3e ignition o*

$or 2e3i4les wit3 1*6 lB9+ , and 1*; lB5 , engine

Deta43 air guide 3ose 1 and unplug

4onne4tor ! =rom air mass meter*

$or 2e3i4les wit3 1*; litreB5 , engine

'emo2e t3e air 3ose / =rom t3e air


65/167

0nplug 4onne4tor =rom re2ersing lig3t

swit43 $+arrow*

As o= gearbox manu=a4turing date /

0nplug plug o= t3e re2ersing lig3t swit43

$+arrow /*

Ve3i4les wit3 1*+ ltr* engine

'emo2e t3e bra4et =or t3e wiring o= t3e

lambda probe arrow 1? to t3is end

release t3e


66/167

t3e gearbox*

'elease s4rews ! and remo2e 4ontrol

4onsole / wit3 4oupling rods and

gearbox s3i=t le2er =rom gearbox*

0ns4rew t3e sla2e 4Elinder =rom t3e

gearbox arrows pla4e to t3e top and

se4ure wit3 wire? do not open t3e line

sEstem*

#ote

Do not depress t3e 4lut43 pedal*

'emo2e t3e eart3 strap =rom t3e

engineBgearbox 4onne4ting s4rew 1*

0ns4rew 4able 4lip / at top starter

arrow and laE aisde*

'elease top


67/167

Install supporting de2i4e MP;! 71

!!!A8*

#ote

,3en installing t3e li=ting 3oos o= t3e

supporting de2i4e? paE attention to 3oseand 4able 4onne4tions in t3e area o= t3e

li=ting eEes to a2oid damaging t3em wit3

t3e engine*

Slig3tlE raise t3e engineBgearbox unit 2ia

t3e spindles o= t3e supporting de2i4e

MP;! 71!!!A8*

0ns4rew bra4et =or PAS line =rom t3e

double s4rew arrow 1*

0ns4rew t3e


68/167

'emo2e noise insulation 4ompletelE* To

t3is end uns4rew s4rews arrows*

'emo2e t3e le=t w3eel3ouse liner > (odE

,or > 'ep* &r*66*

'emo2e t3e starter > "le4tri4al SEstem

> 'ep* &r*!9*

I= present? remo2e 3eat s3ield =or dri2e

s3a=t =rom t3e engine arrows*

Turn w3eels to =ull le=t*

'emo2e dri2e s3a=ts =rom Gange s3a=ts

and tie up as =ar as possibleQ do not

damage t3e sur=a4e prote4tion*

$or 2e3i4les wit3 1*6 lB9+ , and 1*; lB5

, engine

6

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp82800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp82800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp83216http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp84624http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp85040http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp82800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp82800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp83216http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp84624http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp85040http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp85040


69/167

'emo2e small 4o2er plate A =or GEw3eel

be3ind t3e rig3t Gange s3a=t arrows*

0nbolt pendulum support arrows*

0ns4rew rear engineBgearbox 4onne4ting

s4rew arrow A*

$or 2e3i4les wit3 1*6 litreB9+ , engine

'emo2e 4atalEti4 4on2erter > 1*6 lB9+ ,

"ngine? Me43ani4s > 'ep* &r*!6*

$or 2e3i4les wit3 1*6 lB55 , and 1*; lB5

, engine

6;

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp95136http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp95136http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp95568http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp95136http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp95136http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp95568


70/167

'elease 4lamping slee2e A and

separate t3e ex3aust sEstem*

$or 2e3i4les wit3 1*6 litreB55 , engine

Separate =ront ex3aust pipe =rom

4atalEti4 4on2erter? to do so uns4rew

nuts arrows*

0nbolt pendulum support > An43or?


71/167

0ns4rew rear engineBgearbox 4onne4ting

s4rews A and ( and remo2e small 4o2er

plate =o GEw3eel C*

#ote

PaE attention to t3e 4orre4t


72/167

Position gearbox Ra4 below 2e3i4le?

arrow sEmbol ( 7 > An43or? $ig* V/+

!5998 on adRusting plate points in t3e

dire4tion o= tra2elB2e3i4le*

Align adRusting plate parallel to t3egearbox and lo4 se4uring mount at

gearbox*

'emo2e t3e bottom


73/167

(d>ust supporting arm at slide with locing pin

-arrow-)

*umber of ,isible holes ? #)

6aise gearbox with worshop crane andgearbox suspension de,ice -&;-/"# $-)

;lace down gearbox@ e)g) in a transport

container)

Installing t3e gearbox

T3e installation o= t3e gearbox o44urs in re2erse order* Install engineBgearbox mounting =ree

o= stress > 'ele2ant "ngine? Me43ani4sQ 'ep*&r* 1*

#ote

tI= t3e gearbox is repla4ed? i= pro2ided alwaEs re C3apter*

tClean spline o= dri2e s3a=t and applE a t3in C3assis > 'ep* &r*+*

t Installing starter and 4able > "le4tri4al SEstem > 'ep* &r*!9*

t C3e4 gear oil le2el > C3apter*

t Setting t3e s3i=t me43anism > C3apter*

t AdRust assemblE bra4et > "ngine > 'ep* &r*1*

tI= t3e batterE eart3 strap is dis4onne4ted and 4onne4ted? 4arrE out additional operations


Tig3tening tor:ues

9/

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp37440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39200http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42272http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp42656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43680http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44064http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45088http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46336http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp47584http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp47968http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49104http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp49488http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45088http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp37440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39200http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42272http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp42656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43680http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44064http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46336http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp47584http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp47968http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49104http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp49488


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&earbox to engine

Ve3i4les wit3 1*6 ltr*B55 ,

engine

Position S4rew tE #m

1 M1! x 55 1

!?/ 18 M1! x 55 1

+ 18 M1! x 1! 1

5 M1! x 55 1

6?9 M1 x 5 1 +5

M1! x /5 1 !

; M1! x 55 1

A Dowel slee2es =or 4entering

18 S4rew wit3 t3readed pin M

9+


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&earbox to engine

Ve3i4les wit3 1*6 ltr*B9+ , and 1*6 ltrB95, engine


1 M1! x 65 1

! 18 M1! x 65 1

/?+ 18 M1! x 1+ 1

5? 6? 9 M1 x 5 1 +5

M1! x 1



&earbox to engine

Ve3i4les wit3 1*; ltr*B5 , engine


1 M1! x 55 1

95


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! 18 M1! x 55 1

/?+ 18 M1! x 1+ 1

5? 6? 9 M1 x 5 1 +5

M1! x 55 1



&earbox to engine

Ve3i4les wit3 1*+ ltr*B55 ,

engine


1 M1! x 65 1

!?/ 18 M1! x 65 1

+ 18 M1! x 1+ 1

5 M1! x 65 1

6?9 M1 x 5 1 +5

M1! x /5 1 !

; M1! x 65 1



96


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&earbox to bodE

'epla4e s4rews A and (*

S4rews A 6 #m ;J18

S4rews ( + #m ;J18

l 18 ;J 4orresponds to a :uarter turn*

Component Tig3tening tor:ue

Co2er plate =or GEw3eel 1 #m

Sla2e 4Elinder to gearbox !5 #m

Console =or s3i=t me43anism on gearbox up to 9*; !5 #m

Console =or s3i=t me43anism on gearbox as o= *; 18 !5 #m

S3i=t rod to gearbox 18 ! #m

&earbox s3i=t le2er to gearbox 18 ! #m

Dri2e s3a=t to Gange s3a=t > C3assis > 'ep* &r*+

Pendulum support > "ngine > 'ep* &r*1

%eat s3ield o= dri2e s3a=t to engine > C3assis > 'ep* &r*+

18 'epla4e nut > "le4troni4 Catalogue o= Original Parts

99

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp308064http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp308528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp311680http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp312096http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp315120http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp315536http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp317024http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp308064http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp308528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp311680http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp312096http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp315120http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp315536http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp317024


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Inspe4t gear oil

&earbox oil spe4i "le4troni4 Catalogue o= Original Parts*

Turn steering to =ull le=t lo4*

'emo2e t3e le=t noise insulation? i= present? below t3e engineBgearbox > (odE ,or

> 'ep* &r*5*

0ns4rew s4rew arrow =or inspe4ting

gear oil*

T3e gear oil le2el is at t3e 4orre4t le2el i=

t3e gear is


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Disassembling and assembling t3e gearbox

&earbox o2er2iew

1 Clut43 3ousing

: repairing > C3apter

! Dierential gear

: disassembling and assembling > C3apter

/ Output s3a=t

disassembling and assembling

+ Dri2e s3a=t


5 1st gear

6 'e2erse gear

9 !nd gear

9;

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37984http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39488http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41872http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37984http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39488http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41872


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Co2er =or gearbox 3ousing


; 5t3 gear

1 +t3 gear

11 /rd gear

1! &earbox 3ousing

SummarE o= 4omponents disassembling and assembling t3e gearbox

Mounting se:uen4e disassembling and assembling t3e gearbox > C3apter

I SummarE o= 4omponents 'emo2ing and installing gearbox 3ousing 4o2er and 5t3 gear

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37424http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37424


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> C3apter

II SummarE o= 4omponents remo2ing and installing gearbox 3ousing and gears3i=t s3a=t

> C3apter

III SummarE o= 4omponents 'emo2ing and installing t3e dri2e s3a=t? output s3a=t?

dierential gear and s3i=t =ors > C3apter

SummarE o= 4omponents 'emo2ing and installing gearbox 3ousing 4o2er and 5t3 gear

1 !5 #m

: M x 6!

: + pie4es

! S4rew 4ap


1

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39424http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41024http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp42656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39120http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39424http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41024http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp42656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39120


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: installing > An43or

/ !5 #m

: M x 5

: ! pie4es? one s4rew is lo4ated under t3e s4rew 4ap Pos* !

+ Co2er =or gearbox 3ousing


5 Sliding slee2eBsEn43roniHer bodE =or 5t3 gear wit3 stop ring


6 Cir4lip

: alwaEs repla4e damaged or o2ertensioned 4ir4lips > "le4troni4 Catalogue o= Original Parts

9 T3rust was3er

&ear pinion =or 5t3 gear

: $itting position groo2e to t3e top

; .o4 was3er


1 5t3 gear s3i=t =or

: adRust > An43or

11 M19 x 1? 15 #m

: sel=lo4ing


: new s4rew is mi4ro en4apsulated 7t3read wit3 lo4ing agent8

: to release or tig3ten t3e s4rew obser2e mounting se:uen4e > C3apter

SummarE o= 4omponents remo2ing and installing gearbox 3ousing and s3i=t me43anism

!

http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39760http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41920http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43504http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45008http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp47056http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48080http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49600http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39760http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41920http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43504http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45008http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp47056http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48080http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49600http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50656


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Skoda Octavia Mk1 - 06 - Power Transmission Gearbox 02K

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